Electrically Conductive Film

ABSTRACT

The invention relates to an electrically conductive film ( 10 ) having an electrically nonconductive substrate layer ( 12 ), and an electrically conductive metal layer ( 14 ) that has a structure produced by material removal and that on a first side is joined, at least in sections, to the substrate layer ( 12 ).

The invention relates to an electrically conductive film having anelectrically nonconductive substrate layer, and an electricallyconductive metal layer that has a structure produced by material removaland that on a first side is joined, at least in sections, to thesubstrate layer.

The invention further relates to an electrical heating device having oneor more electrically conductive films, a cell voltage tap, and a cellcontacting unit for a battery, in particular a vehicle battery, havingone or more electrically conductive films.

The invention further relates to a manufacturing method for anelectrically conductive film, having the steps: providing a film thathas at least one electrically nonconductive substrate layer and oneelectrically conductive metal layer, and producing a structure of themetal layer by means of a material-removing process, in particular amachining process.

As a result of the increasing electrification of current vehicles, thereis a growing demand for electrically conductive structures that may beintegrated into various vehicle components in a space-saving and/orunobtrusive manner.

For example, there is a great need for flat, elastic heating devicesthat may be integrated, for example, into a vehicle seat, a steeringwheel, or other contact surfaces inside a vehicle.

In addition to such comfort-oriented application areas, flatelectrically conductive structures are also needed for the drive trainof electric vehicles and hybrid vehicles, for example to carry outspace-saving contacting of unit cells of a vehicle battery or to allowmeasurement of their individual voltages.

Electrically conductive films on the one hand take up littleinstallation space, and on the other hand have sufficient deformability,so that they are suitable for use in the comfort sector and in the areaof electrical drives of vehicles.

However, the known electrically conductive films and other electricallyconductive objects, such as flat ribbon cables, are not very suitablefor a number of applications. In particular, the known electricallyconductive films have insufficient mechanical strength and/ordeformability. Flat ribbon cables lack an electrically conductivestructural pattern, so that they are not usable in many applicationareas. In addition, the manufacture is often complicated and costly.

Furthermore, manufacturing methods are routinely used in the prior artin which harmful or even toxic substances are produced. Thesedisadvantages are associated in particular with the etching ofelectrically conductive structures.

The object underlying the invention, therefore, is to provide anelectrically conductive structure that is universally usable and thatstill at least partially overcomes the stated disadvantages.

The object is achieved by an electrically conductive film of the typestated at the outset, wherein the structure of the metal layer has oneor more strip conductors that have at least one bent section.

The invention makes use of the finding that a multilayer film may bearbitrarily structured by material removal, for example by amaterial-removing process, so that electrically conductive films may bemanufactured for different fields of application. Complex electricallyconductive structural patterns may be produced as the result of one ormore strip conductors having at least one bent section. Thus, theelectrically conductive film is essentially universally usable as ribboncable, for example. Within the meaning of the invention, a bent sectionof a strip conductor is understood to mean a strip conductor sectionthat has a change in direction within the metal layer. Such a change indirection may be present, for example, when the strip conductor has acorner section that joins two linear strip conductor sections together.It is particularly advantageous when the electrically conductive film isused within a cell contacting unit for a battery. As a result of thestructure of the metal layer having been produced by machining, inaddition the need for using harmful substances for etching thestructuring is eliminated.

In one preferred refinement of the electrically conductive film, thestructure of the metal layer has one or more strip conductors, whereinat least one strip conductor includes multiple strip conductor sectionswhose strip conductor widths differ from one another. In particular, theindividual strip conductor sections of the at least one strip conductorhave strip conductor widths in the range between 5 millimeters and 1millimeter. Preferred strip conductor widths are 4.2 millimeters, 3.8millimeters, 3.2 millimeters, and 2.3 millimeters, for example.

In another embodiment of the electrically conductive film according tothe invention, the multiple strip conductor sections of the at least onestrip conductor extend in an offset manner and/or in parallel to oneanother. For an offset and parallel course of multiple strip conductorsections having different strip conductor widths, a transition sectionof the strip conductor results in each case between the strip conductorsections. This transition section may have the strip conductor width ofone of the strip conductor sections that the transition section joinstogether. Alternatively, the transition section may have some otherstrip conductor width.

Also preferred is an electrically conductive film for which the stripconductor width of successive strip conductor sections of the at leastone strip conductor increases or decreases along the course of the stripconductor. In this way, strip conductors may be implemented which havean overall resistance of less than 1 ohm over their length. Extremelythin strip conductors having a low overall resistance may thus beimplemented. In addition, due to the different strip conductor widths ofone or more strip conductors, the strip conductor design may be adaptedto the available free surface area of the electrically nonconductivesubstrate layer. The overall width of all strip conductors may increaseand/or decrease.

One particularly preferred embodiment of the electrically conductivefilm according to the invention has an electrically nonconductive coverlayer having a structure that is produced by material removal, whereinthe metal layer on a second side is joined, at least in sections, to thecover layer. The substrate layer preferably has an elasticallydeformable design, and thus allows the implementation of a deformablefilm that has a complex electrically conductive structure. The coverlayer is preferably used as mechanical overload protection, which due tothe elastic deformability prevents the electrically conductive structureof the metal layer from being damaged or destroyed.

In another embodiment of the electrically conductive film according tothe invention, the substrate layer has a layer thickness in a range of0.024 millimeter to 0.2 millimeter, the metal layer has a layerthickness in a range of 0.009 millimeter to 0.030 millimeter, and/or thecover layer has a layer thickness in a range of 0.024 millimeter to 0.2millimeter.

The electrically conductive film according to the invention is furtheradvantageously refined in that the structure of the cover layer that isproduced by material removal is the same, in its entirety or insections, as the structure of the metal layer that is produced bymaterial removal. In the area or areas in which the structure of thecover layer and the structure of the metal layer are the same, the metallayer and the cover layer have the same contour. It is particularlyadvantageous when the electrically conductive film is used for anelectrical heating device. In addition, the structure of the cover layerthat is produced by material removal may be different, in its entiretyor in sections, from the structure of the metal layer that is producedby material removal.

In another embodiment of the electrically conductive film according tothe invention, the material of which the substrate layer is made has alower modulus of elasticity than the material of which the cover layeris made. As the result of the material of which the substrate layer ismade having a lower modulus of elasticity than the material of which thecover layer is made, when there is a tensile stress on the electricallyconductive film, the majority of the forces are absorbed by the coverlayer, and excessive stretching or elongation of the electricallyconductive film is avoided. The risk of damage and failure of theelectrically conductive film under tensile stress is reducedsignificantly by the prevention of excessive stretching or elongation ofthe electrically conductive film.

Also preferred is an electrically conductive film according to theinvention in which the difference between the modulus of elasticity ofthe material of which the substrate layer is made and the modulus ofelasticity of the material of which the cover layer is made is at least20 megapascals. In a large number of application areas, a difference of20 megapascals is adequate on the one hand to be able to ensuresufficient elastic deformability of the electrically conductive film,and on the other hand to achieve suitable protection from excessivetensile stress on the electrically conductive film.

In one advantageous embodiment of the electrically conductive filmaccording to the invention, the substrate layer is made of athermoplastic elastomer, in particular a thermoplastic polyurethane.Thermoplastic elastomers may be welded, and thus allow a connection tobe established that is resistant and, if necessary for the particularpurpose, watertight. Alternatively, the substrate layer may be made of athermoplastic copolyamide, a thermoplastic polyester elastomer, athermoplastic copolyester, a thermoplastic olefin-based elastomer, astyrene block copolymer, a thermoplastic vulcanized material, or acrosslinked thermoplastic olefin-based elastomer.

In one refinement of the electrically conductive film according to theinvention, the material of which the substrate layer is made has amodulus of elasticity in the range of 10 to 100 megapascals. A modulusof elasticity in the range of 10 to 100 megapascals allows sufficientelastic deformation in order to use the electrically conductive film,for example, as an electrical heating device for bent or curved contactsurfaces in the vehicle interior. However, the electrically conductivefilm may also be used as an electrical heating device for electricalcomponents of the drive train having a bent or curved basic shape.

In addition, an electrically conductive film according to the inventionis advantageous in which the substrate layer and/or the cover layerare/is made of a thermoplastic plastic, in particular polyethylenenaphthalate or polyethylene terephthalate. Polyethylene naphthalate hashigh thermostability, so that the electrically conductive film may alsobe used at elevated temperatures and/or as an integral part of anelectrical heating device. Polyethylene terephthalate has a high rupturestrength and good wear characteristics. Thus, when polyethyleneterephthalate is used, the risk of damage is reduced, and anelectrically conductive film with a comparatively long service life isprovided.

Also preferred is an electrically conductive film according to theinvention in which the material of which the substrate layer and/or thecover layer are/is made has a modulus of elasticity in the range of 120to 1200 megapascals. A modulus of elasticity in the range of 120 to 1200megapascals ensures sufficient rigidity in order to provide anelectrically conductive film that is resistant to mechanical tensilestress. In addition, when the material of which the cover layer is madehas a modulus of elasticity in the range of 120 to 1200 megapascals,extremely precise material removal from the cover layer may take placeduring the manufacture, so that complex structural patterns with smalltolerances in the cover layer may be produced.

In one advantageous embodiment of the electrically conductive filmaccording to the invention, the electrically conductive metal layer ismade of copper, a copper alloy, aluminum, copper-clad aluminum (CCA),and/or an aluminum alloy. Copper and aluminum have a high electricalconductivity, and are therefore particularly suited for use as a metallayer of the electrically conductive film. In addition, copper andaluminum allow a precise material-removing, in particular machining,process, so that complex structural patterns and/or finely structuredstrip conductors with small tolerances in the metal layer may beproduced. In one particularly preferred embodiment, the electricallyconductive metal layer is made of copper-clad aluminum. Copper-cladaluminum is less expensive than pure copper, since aluminum is lesscostly than copper. In addition, despite the required largercross-sectional area, conductors made of copper-clad aluminum are morelightweight than solid copper conductors, with the same electricalconductivity.

In one embodiment, the electrically conductive film according to theinvention has an electrically nonconductive supporting layer that isjoined to the metal layer or to the side of the substrate layer oppositefrom the metal layer. If the electrically conductive film has no coverlayer, the electrically conductive film may thus have a three-layerdesign. If the electrically conductive film has a cover layer, theelectrically conductive film may thus have a four-layer design. Duringthe manufacturing process, the supporting layer is temporarily joined tothe electrically conductive film in order to ensure sufficient rigidityof the conductive film during the material removal, in particularmachining. The connection between the substrate layer or the metal layerand the supporting layer preferably has a mechanically or chemicallydetachable design. In particular, the adhesive action between thesubstrate layer or the metal layer and the supporting layer is less thanthe adhesive action between the other layers of the electricallyconductive film.

In another embodiment of the electrically conductive film according tothe invention, the supporting layer has a layer thickness in a range of0.024 millimeter to 0.2 millimeter.

Also preferred is an electrically conductive film according to theinvention in which the supporting layer is made of a thermoplasticelastomer, in particular a thermoplastic polyurethane. Thermoplasticelastomers may be welded, and thus allow a resistant connection to beestablished. Alternatively, the substrate layer may be made of athermoplastic copolyamide, a thermoplastic polyester elastomer, athermoplastic copolyester, a thermoplastic olefin-based elastomer, astyrene block copolymer, a thermoplastic vulcanized material, or acrosslinked thermoplastic olefin-based elastomer.

In one advantageous refinement of the electrically conductive film, theadhesion of the supporting layer to the substrate layer or to the metallayer allows damage-free detachment of the supporting layer from thesubstrate layer or the metal layer. The adhesive action between thesupporting layer and the substrate layer or the metal layer may beovercome by mechanical action, for example. Alternatively oradditionally, chemical processes may bring about or at least facilitatethe detachment of the supporting layer from the substrate layer or themetal layer.

The object underlying the invention is further achieved by an electricalheating device of the type mentioned at the outset, wherein the one ormore electrically conductive films have a design according to one of theabove-described embodiments. With regard to the advantages andmodifications of the electrical heating device according to theinvention, reference is made to the advantages and modifications of theelectrically conductive film according to the invention.

In one particularly preferred embodiment of the electrical heatingdevice, at least one strip conductor of the metal layer of anelectrically conductive film is designed as a heating conductor and/orextends in a meandering manner in sections. A high heating effect may beachieved due to the meandering design of a heating conductor. Due to thefact that the metal layer may have a complex pattern structure, theelectrically conductive film allows implementation of such a meanderingstructure. Alternatively, multiple strip conductors of the metal layerof the electrically conductive film may each be designed as a heatingconductor and/or may extend in a meandering manner in sections and/ormay be rounded in sections. The one or more heating conductors extendingin a meandering manner may have a plurality of linearly running heatingconductor sections, wherein multiple or all of the linearly runningheating conductor sections may be oriented essentially in parallel toone another. Alternatively or additionally, the one or more heatingconductors extending in a meandering manner, in their entirely or insections, may have a bent, in particular nonuniformly bent, design,wherein the proportion of bent heating conductor sections preferablyexceeds the proportion of linearly running heating conductor sections.The proportion of bent heating conductor sections is preferably greaterthan 75%, particularly preferably greater than 90%.

The object underlying the invention is further achieved by a cellcontacting unit and a cell voltage tap of the type mentioned at theoutset, wherein the one or more electrically conductive films have adesign according to one of the above-described embodiments. With regardto the advantages and modifications of the cell contacting unitaccording to the invention, reference is made to the advantages andmodifications of the electrically conductive film according to theinvention.

In one advantageous embodiment of the cell contacting unit according tothe invention, at least one electrically conductive film has contactingsections that are configured to be electroconductively connected tocontact poles of unit cells. The electrically conductive film is thuspreferably an integral part of a cell voltage tap system. When anelectrically conductive film is used as an integral part of a cellvoltage tap system or a cell contacting unit, it is particularlypreferred that the electrically conductive film has a protective film onthe side facing the unit cells, wherein the presence of such aprotective film is not absolutely necessary.

The electrically conductive film may also be used in flat film antennas.

The object underlying the invention is further achieved by amanufacturing method of the type mentioned at the outset, wherein duringproduction of the structure of the metal layer, one or more stripconductors are produced that have at least one bent section. With regardto the advantages and modifications of the manufacturing methodaccording to the invention, reference is made to the advantages andmodifications of the electrically conductive film according to theinvention. An electrically conductive film according to one of theabove-described embodiments is preferably manufactured by means of themanufacturing method.

In one embodiment of the manufacturing method according to theinvention, the provided film has an electrically nonconductive coverlayer, and the manufacturing method includes the production of astructure of the cover layer by means of a material-removing process, inparticular a machining process. The production of the structure of thecover layer by means of a material-removing process, in particular amachining process, may also include the production of materialelevations in the cover layer by means of an embossing roller and/or theremoval of the material elevations by means of a milling wheel.

Also preferred is a manufacturing method according to the invention inwhich the production of the structure of the metal layer and theproduction of the structure of the cover layer take place at the sametime, and/or the produced structure of the cover layer is the same, inits entirety or in sections, as the produced structure of the metallayer. An embossing roller preferably produces enough projectingmaterial elevations in the metal layer and the cover layer that thematerial elevations in the metal layer and the cover layer, produced bythe embossing roller, are at the same time removed by the milling wheel.By use of an embossing roller that has embossing sections with differentheights, the manufacturing method according to the invention may alsoproduce electrically conductive films whose various layers havedifferent structural patterns.

Preferred embodiments of the invention are explained and described ingreater detail below with reference to the appended drawings, which showthe following:

FIG. 1 shows the manufacture of an electrically conductive filmaccording to the invention in a schematic illustration;

FIG. 2 shows the manufacture of an electrically conductive filmaccording to the invention in a schematic illustration;

FIG. 3 shows the manufacture of an electrically conductive filmaccording to the invention in a schematic illustration;

FIG. 4 shows the manufacture of an electrically conductive filmaccording to the invention in a schematic illustration;

FIG. 5 shows one exemplary embodiment of the electrical heating deviceaccording to the invention in a schematic illustration;

FIG. 6 shows one exemplary embodiment of the cell contacting unitaccording to the invention in a schematic illustration;

FIG. 7 shows one exemplary embodiment of the manufacturing methodaccording to the invention in a block diagram;

FIG. 8 shows the width profile of multiple strip conductors of a metallayer of an electrically conductive film according to the invention; and

FIG. 9 shows one exemplary embodiment of the electrical heating deviceaccording to the invention in a schematic illustration.

FIG. 1 on the left side shows an electrically conductive film 10 havingan electrically nonconductive substrate layer 12 and an electricallyconductive metal layer 14.

The substrate layer 12 is made of a material that has a modulus ofelasticity in the range of 120 to 1200 megapascals. For example, thesubstrate layer 12 may be made of polyethylene naphthalate orpolyethylene terephthalate.

The metal layer 14 is made of copper and aluminum, for examplecopper-clad aluminum, and on a first side is joined to the substratelayer 12.

The right side of FIG. 1 shows the film 10 illustrated on the left sideof FIG. 1, after material removal from the metal layer 14 has takenplace. The produced structure of the metal layer 14 has a stripconductor 20 having a bent section (concealed).

FIG. 2 on the left side shows an electrically conductive film 10 havingan electrically nonconductive substrate layer 12, an electricallyconductive metal layer 14, and an electrically nonconductive cover layer16.

The substrate layer 12 is made of a material that has a modulus ofelasticity in the range of 120 to 1200 megapascals. For example, thesubstrate layer 12 may be made of polyethylene naphthalate orpolyethylene terephthalate.

The metal layer 14 is made of copper and aluminum, for examplecopper-clad aluminum, and on a first side is joined to the substratelayer 12 and on a second side is joined to the cover layer 16.

The cover layer 16 is made of a material that has a modulus ofelasticity in the range of 120 to 1200 megapascals. For example, thecover layer 16 may be made of polyethylene naphthalate or polyethyleneterephthalate.

The right side of FIG. 2 shows the film 10 illustrated on the left sideof FIG. 2, after material removal from the metal layer 14 and the coverlayer 16 has taken place. The produced structure of the metal layer 14is different from the produced structure of the cover layer 16.

FIG. 3 on the left side shows an electrically conductive film 10 havingan electrically nonconductive substrate layer 12, an electricallyconductive metal layer 14, an electrically nonconductive cover layer 16,and an electrically nonconductive supporting layer 18.

The substrate layer 12 is made of a material that has a modulus ofelasticity in the range of 10 to 100 megapascals. For example, thesubstrate layer 12 may be made of a thermoplastic elastomer such as athermoplastic polyurethane.

The metal layer 14 is made of copper and aluminum, for examplecopper-clad aluminum, and on a first side is joined to the substratelayer 12 and on a second side is joined to the cover layer 16.

The cover layer 16 is made of a material that has a modulus ofelasticity in the range of 120 to 1200 megapascals. For example, thecover layer 16 may be made of polyethylene naphthalate or polyethyleneterephthalate. The material of which the substrate layer 12 is made thushas a lower modulus of elasticity than the material of which the coverlayer 16 is made. In addition, the difference between the modulus ofelasticity of the material of which the substrate layer 12 is made andthe modulus of elasticity of the material of the material of which thecover layer 16 is made is greater than 20 megapascals.

The supporting layer 18 is made of a material that has a modulus ofelasticity in the range of 120 to 1200 megapascals. For example, thesupporting layer 18 may be made of polyethylene naphthalate orpolyethylene terephthalate, wherein the material thickness of thesupporting layer 18 is greater than the respective material thicknessesof the other layers 12, 14, 16. In addition, the supporting layer 18 isjoined to the side of the substrate layer 12 opposite from the metallayer 14, wherein the adhesion of the supporting layer 18 to thesubstrate layer 12 allows damage-free detachment of the supporting layer18 from the substrate layer 12.

The right side of FIG. 3 shows the film 10 illustrated on the left sideof FIG. 3, after material removal from the metal layer 14 and the coverlayer 16 on the one hand, and detachment of the supporting layer 18 fromthe substrate layer 12 on the other hand, have taken place. The producedstructure of the metal layer 14 differs from the produced structure ofthe cover layer 16. However, it is also conceivable for the materialremoval to take place in such a way that the produced structure of thecover layer 16 is the same, in its entirety or in sections, as theproduced structure of the metal layer 14.

FIG. 4 on the left side shows an electrically conductive film 10 havingan electrically nonconductive substrate layer 12, an electricallyconductive metal layer 14, and an electrically nonconductive supportinglayer 18.

The substrate layer 12 is made of a material that has a modulus ofelasticity in the range of 120 to 1200 megapascals. For example, thesubstrate layer 12 may be made of polyethylene naphthalate orpolyethylene terephthalate.

The metal layer 14 is made of copper and aluminum, for examplecopper-clad aluminum, and on a first side is joined to the substratelayer 12.

The supporting layer 18 is made of a material that has a modulus ofelasticity in the range of 120 to 1200 megapascals. For example, thesupporting layer 18 may be made of polyethylene naphthalate orpolyethylene terephthalate, wherein the material thickness of thesupporting layer 18 is greater than the respective material thicknessesof the other layers 12, 14. In addition, the supporting layer 18 isjoined to the metal layer 14, wherein the adhesion of the supportinglayer 18 to the metal layer 14 allows damage-free detachment of thesupporting layer 18 from the metal layer 14.

The right side of FIG. 4 shows the film 10 illustrated on the left sideof FIG. 4, after material removal from the metal layer 14 and thesubstrate layer 12 on the one hand, and detachment of the supportinglayer 18 from the metal layer 14 on the other hand, have taken place.The produced structure of the metal layer 14 and the produced structureof the substrate layer 12 are the same.

FIG. 5 shows an electrical heating device 100 having an electricallyconductive film 10. The electrically conductive film 10 has anelectrically nonconductive substrate layer 12 and an electricallyconductive metal layer 14.

The metal layer 14 includes a structure that is produced by materialremoval, and on a first side is joined to the substrate layer 12. Thestructure of the metal layer 14 has a strip conductor 20 that isdesigned as a heating conductor and that in the sections 24 a-24 eextends in a meandering manner and thus includes a plurality of bentsections 22. A contact section 26 a, 26 b is situated in each case atthe ends of the heating conductor, wherein the heating conductor of theheating device 100 is suppliable with electrical energy via thecontacting sections 26 a, 26 b.

FIG. 6 shows a cell contacting unit 200 for a battery, namely, a vehiclebattery. The cell contacting unit 200 has an electrically conductivefilm 10 that includes an electrically nonconductive substrate layer 12and an electrically conductive metal layer 14.

The metal layer 14 has a structure that is produced by material removal,wherein the structure of the metal layer 14 includes multiple stripconductors 20 that have a plurality of bent sections 22.

The electrically conductive film 10 also includes contacting sections 26a-26 d that are electroconductively connected to contact poles 204 a-204d of unit cells 202 a-202 d.

FIG. 7 shows a manufacturing method for an electrically conductive film10. The manufacturing method is initiated by the following step:

300) providing a film 10 having an electrically nonconductive substratelayer 12, an electrically conductive metal layer 14, and an electricallynonconductive cover layer 16.

After the film 10 has been provided, the following steps may be carriedout:

302) producing a structure of the metal layer 14 by means of a machiningprocess; and

308) producing a structure of the cover layer 16 by means of a machiningprocess.

During production of the structure of the metal layer 14, multiple stripconductors 20 are created, wherein the production of the structure ofthe metal layer 14 by means of a machining process comprises thefollowing two steps:

304) producing material elevations in the metal layer 14 by means of anembossing roller; and

306) removing the material elevations in the metal layer 14 by means ofa milling wheel.

The product ion of the structure of the cover layer 16 by means of amachining process analogously comprises the following two steps:

310) producing material elevations in the cover layer 16 by means of theembossing roller; and

312) removing the material elevations in the cover layer 16 by means ofthe milling wheel.

The production of the structure of the metal layer 14 and the productionof the structure of the cover layer 16 take place at the same time,namely, by the embossing roller producing sufficiently projectingmaterial elevations in the metal layer 14 and the cover layer 16 so thatthe material elevations in the metal layer 14 and the cover layer 16produced by the embossing roller may at the same time be removed by themilling wheel. The produced structure of the cover layer 16 is thus thesame as the produced structure of the metal layer 14. Alternatively,however, by using an embossing roller that has embossing sections withdifferent heights, it is also possible to produce electricallyconductive films 10 whose various layers have different structuralpatterns.

FIG. 8 shows the structure of multiple strip conductors 20 of a metallayer 14. All strip conductors 20 in each case have multiple stripconductor sections 28 a-28 e having strip conductor widths B1-B5 thatare different from one another. The strip conductor sections 28 a-28 eof the strip conductors 20 extend in an offset manner and in parallel toone another. The strip conductor width B1-B5 of successive stripconductor sections 28 a-28 e increases along the course of the stripconductor. The strip conductor section 28 a has a strip conductor widthB1 of 4.2 millimeters. The strip conductor section 28 b has a stripconductor width B2 of 3.8 millimeters. The strip conductor section 28 chas a strip conductor width B3 of 3.2 millimeters. The strip conductorsection 28 d has a strip conductor width B4 of 2.3 millimeters. Thestrip conductor section 28 e likewise has a strip conductor width B5 of2.3 millimeters. Bent transition sections 30 a-30 d are situated betweenthe strip conductor sections 28 a-28 e. The ends of the individual stripconductors 20 are positioned on one side, laterally offset relative toone another.

FIG. 9 shows an electrical heating device 100 having an electricallyconductive film 10. The electrically conductive film 10 has anelectrically nonconductive substrate layer 12 and an electricallyconductive metal layer 14.

The metal layer 14 includes a structure that is produced by materialremoval, and on a first side is joined to the substrate layer 12. Thestructure of the metal layer 14 has two strip conductors 20 that aredesigned as heating conductors, and that extend continuously in ameandering manner and thus include a plurality of bent heating conductorsections 22. The two heating conductors that extend in a meanderingmanner each have a nonuniformly bent design in sections, wherein theproportion of bent heating conductor sections is greater than 90%.Contacting sections 26 a, 26 b are situated on the respective ends ofthe heating conductors, wherein the heating conductors of the heatingdevice 100 are suppliable with electrical energy via the contactingsections 26 a, 26 b.

The invention preferably relates to a heating element having anelastically and/or plastically deformable substrate, a strip conductorthat is situated on the substrate, and a cover layer whose base area iscongruent with the base area of the strip conductor, and whose tensilestrength is at least twice that of the strip conductor.

The invention further preferably relates to a connection conductorhaving at least one machined electrically nonconductive nonconductorzone, and at least one strip conductor that has a bent course, at leastin sections, within the conductor level.

LIST OF REFERENCE NUMERALS

-   10 electrically conductive film-   12 substrate layer-   14 metal layer-   16 cover layer-   18 supporting layer-   20 strip conductor-   22 bent sections-   24 a-24 e meandering sections-   26 a-26 d contacting sections-   28 a-28 e strip conductor sections-   30 a-30 d transition sections-   100 electrical heating device-   200 cell contacting unit-   202 a-202 d unit cells-   204 a-204 d contact poles-   300-312 method steps-   B1-B5 strip conductor widths

1. An electrically conductive film comprising: an electrically nonconductive substrate layer; an electrically conductive metal layer that has a structure produced by material removal and that on a first side is joined, at least in sections, to the electrically nonconductive substrate layer; and an electrically nonconductive cover layer having a structure that is produced by material removal; wherein the electrically conductive metal layer is located on a second side and is joined, at least in sections, to the cover layer; wherein a material of which the electrically nonconductive substrate layer is made has a modulus of elasticity in the range of 10 to 100 megapascals; wherein the material of which the electrically nonconductive substrate layer is made has a lower modulus of elasticity than the material of which the cover layer is made; and wherein a difference between the modulus of elasticity of the material of which the electrically nonconductive substrate layer is made and the modulus of elasticity of the material of which the cover layer is made is at least 20 megapascals.
 2. An electrically conductive film comprising: an electrically nonconductive substrate layer; an electrically conductive metal layer that has a structure produced by material removal and that on a first side is joined, at least in sections, to the electrically nonconductive substrate layer; and wherein the structure of the electrically conductive metal layer has one or more strip conductors that have at least one bent section; wherein the structure of the metal layer has one or more strip conductors; wherein at least one of the one or more strip conductors includes multiple strip conductor sections whose strip conductor widths differ from one another, and the multiple strip conductor sections of the at least one strip conductor extend in an offset manner and/or in parallel to one another; and wherein the strip conductor width of successive strip conductor sections of the at least one strip conductor increases or decreases along the course of the strip conductor.
 3. (canceled)
 4. (canceled)
 5. (canceled)
 6. (canceled)
 7. The electrically conductive film according to claim 1, wherien the structure of the cover layer that is produced by material removal is a same, in its entirety or in sections, as the structure of the metal layer that is produced by material removal.
 8. (canceled)
 9. (canceled)
 10. The electrically conductive film according to claim 1, wherein the substrate layer is made of a thermoplastic elastomer, in particular a thermoplastic polyurethane.
 11. (canceled)
 12. (canceled)
 13. The electrically conductive film according to claim 2, wherein the material of which the substrate layer and/or the cover layer are/is made has a modulus of elasticity in the range of 120 to 1200 megapascals.
 14. (canceled)
 15. The electrically conductive film according to claim 1, wherein an electrically nonconductive supporting layer that is joined to the metal layer or to the side of the substrate layer opposite from the metal layer.
 16. The electrically conductive film according to claim 1, wherein the supporting layer is made of a thermoplastic elastomer.
 17. The electrically conductive film according to claim 1, wherein the adhesion of the supporting layer to the substrate layer or to the metal layer allows damage-free detachment of the supporting layer from the substrate layer or the metal layer.
 18. An electrical heating device comprising: one or more electrically conductive films; an electrically nonconductive substrate layer; an electrically conductive metal layer that has a structure produced by material removal and that on a first side is joined, at least in sections, to the electrically nonconductive substrate layer; and wherein the electrically conductive metal layer is made of copper, a copper alloy, aluminum, and/or an aluminum alloy; and wherein the substrate layer and/or the cover layer are/is made of a polyethylene naphthalate or polyethylene terephthalate.
 19. The electrical heating device according to claim 18, wherein at least one strip conductor of the metal layer of an electrically conductive film is designed as a heating conductor and/or extends in a meandering manner in sections.
 20. A cell contacting unit for a battery comprising: one or more electrically conductive films; wherein the one or more electrically conductive films are designed according to claim
 1. 21. The cell contacting unit according to claim 20, wherein at least one electrically conductive film has contacting sections that are configured to be electroconductively connected to contact poles of unit cells.
 22. A cell voltage tap for a battery, in particular a vehicle battery, having one or more electrically conductive films; wherein the one or more electrically conductive films are designed according to claim
 1. 23. The cell voltage tap according to claim 22, wherein at least one electrically conductive film of the one or more electrically conductive films has contacting sections that are configured to be electroconductively connected to contact poles of unit cells.
 24. A manufacturing method for an electrically conductive film according to claim 1, comprising the steps: providing a film that has at least one electrically nonconductive substrate layer and one electrically conductive metal layer; and producing a structure of the metal layer by means of a material-removing process; wherein during production of the structure of the metal layer, one or more strip conductors are created which have at least one bent section.
 25. The manufacturing method according to claim 24, wherein the provided film has an electrically nonconductive cover layer wherein the method includes the step of: producing a structure of the cover layer by means of a material-removing process, in particular a machining process.
 26. The manufacturing method according to claim 25, wherein the production of the structure of the metal layer and the production of the structure of the cover layer take place at the same time, and/or the produced structure of the cover layer is a same, in its entirety or in sections, as the produced structure of the metal layer.
 27. The electrically conductive film according to claim 2, wherein an electrically nonconductive supporting layer that is joined to the metal layer or to the side of the substrate layer opposite from the metal layer.
 28. The electrically conductive film according to claim 2, wherein the supporting layer is made of a thermoplastic elastomer, in particular a thermoplastic polyurethane.
 29. A manufacturing method for an electrically conductive film according to claim 18, comprising the steps: providing a film that has at least one electrically nonconductive substrate layer and one electrically conductive metal layer; and producing a structure of the metal layer by means of a material-removing process; wherein during production of the structure of the metal layer, one or more strip conductors are created which have at least one bent section. 